Professional Documents
Culture Documents
All rights reserved. This notice applies to all copyrighted materials included with this product,
including, but not limited to, this manual and software embodied within the product. This manual is
intended for the sole use of the persons to whom it was provided, and any unauthorized distribution
of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in
whole or in part by any means whatsoever without the expressed written permission of Magnetek.
Parts of this product may be covered by one or more of the following patents: 6,598,859, 6,653,804,
6,956,339, 7,190,146, 7,841,583, 8,401,814, 8,669,724, and 8,686,670.
The recommendations in this manual do not take precedence over any of the following requirements
relating to cranes, hoists lifting devices or other material handling equipment which use or include
Magnetek Products:
• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
Magnetek Products are used,
• Plant safety rules and procedures of the employers and the owners of the facilities where the
Magnetek Products are being used,
• Regulations issued by the Occupational Health and Safety Administration (OSHA),
• Applicable local, state or federal codes, ordinances, standards and requirements, or
• Safety standards and practices for the industries in which Magnetek Products are used.
This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners,
users and operators of the Magnetek Products to know, understand and follow all of these
requirements. It is the responsibility of the employer to make its employees aware of all of the above
listed requirements and to make certain that all operators are properly trained. No one should use
Magnetek Products prior to becoming familiar with and being trained in these requirements
and the instructions and safety recommendations for this manual.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury. This signal word is to be limited to the most extreme situations.
WA R N I N G
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury. It may also be used to alert against unsafe practices.
1.866.MAG.SERV
(1.866.624.7378)
World Headquarters
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
1.800.288.8178
EU Market Contact
Magnetek (UK) Ltd.
Unit 3 Bedford Business Centre
Mile Road
Bedford, MK42 9TW UK
Phone: +44.1234.349191
Fax: +44.1234.268955
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more
information, please visit http://www.magnetek.com.
Chapter 1: Introduction
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Assessing the System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Assessing the Drive Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
IMPULSE®•G+ & VG+ Series 4 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
AC Reactor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
S4IF Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
S4I and S4IO Option Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Chapter 2: Installation
IMPULSE®•G+ & VG+ Series 4 System Components And External Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Long Time Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Multiple Drive Installation (Side-by-Side Installation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Drive Derating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Temperature Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Dimensions for IP00/Open Chassis Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Chapter 3: Wiring
IMPULSE®•G+ & VG+ Series 4 Wiring Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Suggested Circuit Protection Specifications and Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Power Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Main Circuit Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Terminal Block Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Insulation Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Interface Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
S4IF DIP Switches and Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Dip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Sinking/Sourcing Mode Selection for Safe Disable Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Control Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
S4IF Control Circuit Terminal Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Wiring the Encoder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Encoder Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Encoder Wiring Diagrams and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Chapter 6: Troubleshooting
Troubleshooting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting Encoder Related Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Fault Code: DEV– Speed Deviation Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Fault Code: PGO-X-S/PGO-X-H–Pulse Generator Signal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Fault Code: BE1–Rollback Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Fault Code: BE2–Torque Proving Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Fault Code: BE3–Brake Release Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Alarm Code: BE6–Brake Proving Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Alarm Code: BE8–Brake Slipping Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Fault Code: OC–Over Current Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Fault Display and Corrective Actions at Auto-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Troubleshooting Option Card Related Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Drive-Side Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Copy Function Related Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Tasks, Errors, and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Introduction
This page intentionally left blank.
Do not touch any circuitry components while the main AC power is on. In addition, wait until the
red “CHARGE” LED is out before performing any service on that unit. It may take as long as 5
minutes for the charge on the main DC bus capacitors to drop to a safe level.
Do not connect the main output terminals (U/T1, V/T2, W/T3) to the incoming, three-phase AC
source.
Before executing a rotational Auto-Tuning, ensure that the motor is disconnected from the drive
train and the electric brake is released. If the electric brake cannot be released, you must ensure
that the brake is disengaged for the entire tuning process.
Read and understand this manual before installing, operating, or servicing this drive. All
warnings, cautions, and instructions must be followed. All activity must be performed by qualified
personnel. The drive must be installed according to this manual and local codes.
Do not connect or disconnect wiring while the power is on. Do not remove covers or touch circuit
boards while the power is on. Do not remove or insert the digital operator while power is on.
Before servicing, disconnect all power to the equipment. The internal capacitor remains charged
even after the power supply is turned off. The charge indicator LED will extinguish when the DC
bus voltage is below 50 VDC. To prevent electric shock, wait at least five minutes after all
indicators are OFF and measure DC bus voltage to confirm safe level.
Do not perform a withstand voltage test on any part of the unit. This equipment uses sensitive
devices and may be damaged by high voltage.
The drive is suitable for circuits capable of delivering not more than 100,000 RMS symmetrical
Amperes. Install adequate branch circuit short circuit protection per applicable codes. Failure to
do so may result in equipment damage and/or personal injury.
The IMPULSE®•G+ and VG+ Series 4 drives share a common power section, and similar
parameters. The parameters and performance differ because the VG+ drives includes a PG-X3
encoder feedback card allowing the drive to perform Flux Vector control of the motor. The G+ drives
operate in V/f or Open Loop Vector control methods, appropriate for traverse or standard hoist
motions. The VG+ drives are typically applied to the non-mechanical load brake hoist motion, and
can be applied to traverse motions where torque control or a wide speed control range is required.
Many IMPULSE®•G+ and VG+ Series 4 parameter functions are common between the two drive
classes. The functions that differ are noted with a “Model” column; this column designates which
parameters are available for a given function. Functions may also be control method dependent;
these differences are noted in the function and parameter details. Table 1-1 below notes which
drives can operate in a particular control method.
The instructions in the following chapters apply to most IMPULSE®•G+ & VG+ Series 4 crane, hoist,
and monorail applications. However, carefully evaluate each specific situation and ensure that the
National Electric Code (NEC) codes and local wiring practices are followed.
These chapters explain how to install the IMPULSE®•G+ & VG+ Series 4 and, to some extent, the
components that it interconnects. It explains how to: assess the drive’s environment, mount the
drive, and wire the drive circuits. It is important to develop a “plan of attack” for both the mounting
and wiring since each task has an effect on the other one. IMPULSE®•G+ & VG+ Series 4 Wiring
Practices is included to provide assistance and reference.
NOTE: If the IMPULSE®•G+ & VG+ Series 4 is part of a Magnetek motor control panel, reference
the control drawings, disregard this chapter, and turn to Chapter 4.
AC Reactor Specifications
Reactors, both as input (line) and output (load) devices, protect adjustable frequency drives, motors,
and other load devices against excessive voltage and current.
The following guidelines may help determine input and output reactor requirements:
• The following tables are only a guideline. The motor FLA should not exceed the reactor FLA.
• Install an input reactor if the power source is greater than 500 kVA.
• Install an output reactor if the distance between the drive and the motor exceeds 150 feet.
• Install an output reactor if a device, such as a power limit switch, is used to disconnect the motor
from the drive. Use a power limit switch early break circuit to fault the drive.
• Install one output reactor per drive for a multiple-drive arrangement requiring reactor protection.
• For a multiple drive arrangement, an input reactor for each drive is recommended for optimal
protection. However, if the drives are within two drive sizes of each other, a single input reactor
can be used. The reactor must be rated at amperage equal to or greater than the sum of the
amperage for all the drives.
• Reactors are most effective when the reactor current rating approaches the drive current rating.
The S4IF has eight optically isolated input terminals which can be used to connect the user input
device to the drive. The eight terminals are multi-function terminals, and are used for speed control
and other controls.
The drive has four 250 VAC, 1.0 Amp relays for output devices. It includes three programmable
multi-function output terminals, and a fault output terminal.
NOTE: The 250 VAC relays must be derated to 48 VAC to comply with CE.
The S4I has four optically isolated input terminals. The S4IO has four optically isolated input
terminals and four dry contact form A relays.
Installation
This page intentionally left blank.
•When preparing to mount the IMPULSE®•G+ & VG+ Series 4 drive, lift it by its base. Never lift
the drive by the front cover, as doing so may cause drive damage or personal injury.
•Mount the drive on nonflammable material.
•The IMPULSE®•G+ & VG+ Series 4 drive generates heat. For the most effective cooling
possible, mount it vertically. For more details, refer to the “IMPULSE®•G+ & VG+ Series 4
Dimensions/Heat Loss-Open Chassis” in this chapter.
•When mounting units in an enclosure, install a fan or other cooling device to keep the
enclosure temperature below 65°C (149°F)*.
In addition, this section will cover information on the components that interconnect with
IMPULSE®•G+ & VG+ Series 4.
Choosing a Location
Be sure that the drive is mounted in a location protected against the following conditions:
• Extreme cold and heat. Use only within the ambient temperature range:
-10°C to +60°C (+14°F to 140°F)*
• Direct sunlight (not for use outdoors)
• Rain, moisture
• High humidity
• Oil sprays, splashes
• Salt spray
• Dust or metallic particles in the air
• Corrosive gases (e.g. sulfurized gas or liquids)
• Radioactive substances
• Combustibles (e.g. thinner, solvents, etc.)
• Physical shock, vibration
• Magnetic noise (e.g. welding machines, power devices, etc.)
* 2 kHz carrier frequency
Inverter drives contain large bus capacitors that have the potential to be reformed. However, printed
circuit boards also contain electrolytic capacitors that may not function after several years without
power. Magnetek recommends replacing the PCBs should the drive’s functionality not be restored
after bus cap reforming. Contact Magnetek Service for questions.
In the event that a capacitor has been stored in a high ambient environment for more than 2 or 3
years, a voltage treatment reformation process to electrolytic capacitors may have to be performed.
When stored above room temperatures for long periods of time, the anode foil may react with the
electrolyte, increasing the leakage current. After storage, the application of even normal voltages to
these capacitors may result in higher than normal leakage currents. In most cases the leakage
current levels will decrease in a short period of time as the normal chemical reaction within the
capacitor occurs. However, in extreme cases, the amount of gas generated may cause the safety
vent to open.
Capacitors, when used in inverter drives that are stored for long periods of time, should be subjected
to a voltage treatment/reforming process as noted below, which will reform the dielectric and return
the leakage current to the initial level.
When mounting drives with the minimum clearing of 0.08 inches (2 mm) according to Figure 2-4, set
parameter L08-35 to 1 while considering derating.
IP00/Open-Chassis Enclosure
Drive operation between -10°C to +60°C (14°F to 140°F) allows CMAA Class F continuous current
without derating.
Side-by-Side Mounting
Drive operation between -10°C and 30°C (14°F to 86°F) allows CMAA Class F continuous current
without derating. Operation between 30°C and 50°C (86°F to 122°F) requires output current
derating.
Wiring
This page intentionally left blank.
WA R N I N G
Before you wire the drive, review the following practices to help ensure that your system is wired
properly.
• Ensure that the encoder wiring is less than 300 feet unless fiber optic cables are used.
• Ensure that the encoder wiring is isolated from the power wiring.
• Ensure that the encoder wiring shield is grounded only at the drive end.
• Connect the incoming three-phase AC source to terminals R/L1, S/L2, T/L3.
• Connect the Motor leads to terminals U/T1, V/T2, W/T3.
• Install a line reactor between the output of the drive in applications that require a disconnecting
means between the drive’s output and motor. Use a “make before break” auxiliary contact with
the disconnect means and the hardware base block of the drive.
• Use hard contacts between the PLC output and the drive 120/24/48 VAC input card. If using a
solid state output from a PLC (TRIAC) to a 120/24/48 VAC input card, use a 5K, 5W resistor
between the signal and X2.
• If the power source is 500 kVA or greater, or more than 10 times the inverter kVA rating, ensure
that there is at least 3% impedance between the power source and the drive input. To
accomplish this, a DC reactor can be installed between inverter terminals 1 and 2, or an AC line
reactor can be used on the input of the drive. Excessive peak currents could damage the input
power supply circuit if there is not enough impedance provided.
• Comply with “Suggested Circuit Protection Specifications” on page 3-6.
• Use time delay fuses, which are sized at 150% of drive's continuous rated input current, for
wiring protection.
• Use appropriate R-C or MOV type surge absorbers across the coil of all contactors and relays in
the system. Failure to do so could result in noise-related, nuisance fault incidents.
• Use external dynamic braking resistors for all applications.
• Do not ground the drive with any large-current machines.
• Before using any welding or high-current machines near the crane, disconnect all line and
ground wiring.
• Do not let the wiring leads come in contact with the drive enclosure.
• Do not connect power factor correction capacitors to the drive input or output; use a sine wave
filter.
• When possible, hard-wire the drive and motor. Do not use sliding collector bars (e.g., festoon
cable).
• If there is a user input device or interface board that is remote, use shielded cable between the
drive input terminals and the interface output terminals or user input device(s).
• Before turning on the drive, check the output circuit (U/T1, V/T2 and W/T3) for possible short
circuits and ground faults.
• Increase the wire size by one gauge for every 250 feet (76.2 meters) between the drive and
motor; suggested for center driven cranes, trolleys, and bridges (voltage drop is significant at
low frequencies).
• When using more than one transformer for the drive's power, properly phase each transformer.
CAUTION
Do NOT connect external dynamic breaking units to drive braking resistor terminal “B2”.
Connect positive external dynamic braking unit terminal(s) to drive terminal “+3” and negative
external dynamic braking unit terminal(s) to drive terminal “-”. When drive terminal “+3” is
unavailable, use terminal “B1”.
CAUTION
The following guidelines are only suggested values. Always conform to local electrical codes
and wiring practices.
Grounding
5. Connect terminal G to the common panel ground. Use ground wiring as specified in “Suggested
Circuit Protection and Wire Size” on page 3-6, and keep the length as short as possible.
• Ground Resistance:
• For 230V class: 100 or less
• For 460V class: 10 or less
• For 575V class: 10 or less
• Never run the IMPULSE®•G+ & VG+ Series 4 drive ground wires in common with welding
machines, or other high-current electrical equipment.
• When more than one drive is used for the same system, ground each directly or daisy-chain to
the ground pole. Do not loop the ground wires.
Figure 3-12: S4IF DIP Switches and Jumper Locations for 120 VAC, 42–48 VAC, and
24 VAC)
Figure 3-13: S4IF DIP Switches and Jumper Locations for 24 VDC
Dip Switches
DIP Switches are described in this section. The functions of the DIP switches are shown in the table
below.
Sinking Mode
Sourcing Mode
(Default)
Terms:
• Multi-Function Digital Input (MFDI)
• Multi-Function Digital Output (MFDO)
• Multi-Function Analog Input (MFAI)
• Multi-Function Analog Output (MFAO)
Figure 3-14: S4IF Control Circuit Terminal Diagram (120 VAC, 42–48 VAC, 24 VAC)
Safe Torque Off disable the drive power section for mechanical maintenance, E-stops, or
redundancy safety monitor controller intervention. The feature provides safe removal of motor torque
without removal of power to the drive. This is a standard feature on the IMPULSE®•G+ & VG+
Series 4. A Safe Disable Status Monitor for error detection in the safety circuit is also provided.
The Safe Disable circuit (Figure 3-16) consists of two independent input channels (H1 and H2) that
can block the output transistors and provide a monitoring output channel (DM+ and DM-) to indicate
the status of those input channels.
The input can use the internal 24VDC power supply of the drive or an external power supply, and it
will support Sink mode or Source mode. The mode selected for the digital input terminals S1 to S8
by jumper S3 will also be used for the Safe Disable inputs.
NOTE: Terminals H1, H2, DM+, and DM- on 575V class models are designed to the functionality,
but are not certified to IEC/EN 61800-5-1, ISO/EN 13849 Cat. 3, IEC/EN 61508 SIL2,
Insulation coordination: class 1.
Before you wire the encoder circuit, refer to the specification tables 3-10 and 3-11 on page 3-25 and
“Suggested Circuit Protection Specifications and Wire Size” on page 3-6.
To wire the encoder circuit for IMPULSE®•VG+ Series 4 (assuming the cover and keypad are
detached):
1. Direct-couple the encoder to the motor shaft, using a zero-backlash-type coupling.
NOTE: Do not connect the encoder to the motor with roller chain or gear drive. If unable to
direct-couple the encoder, use a timing belt to drive the encoder. (Contact Magnetek
for encoder kits.) Also, do not connect the encoder to the low-speed shaft of a speed
reducer.
2. Connect the encoder to the PG-X3 Encoder Interface Card. Refer to Figure 3-17: “PG-X3
Encoder Card Wiring” on page 3-25.
NOTE: Use twisted-pair, shielded cable W100W impedance (Magnetek R-20/6, R-22/6,
Belden 9730, or Brand Rex T-11651). Strip the encoder wires .25 in. (5.5 mm). Keep
the wiring length less than 300 feet (for cable lengths greater than 300 feet, contact
Magnetek for information on available fiber optic cable).
3. Ground the shielded cable to Terminal FE of the PG-X3 Encoder Interface Card (ground only
one end of the shielded cable).
NOTE: For LakeShore encoders, the shield connection is not considered “Ground.” The
shield should be grounded.
4. Whenever possible, the encoder cable should be wired in a continuous run between the motor
and drive. If it cannot be a direct run, the splice should be in its own junction box and isolated
from the power wires.
NOTE: See PG-B3 Open Collector Encoder Card manual for wiring and terminal descriptions.
Getting Started
This page intentionally left blank.
Precautions
• Only start the motor if motor shaft rotation is stopped.
• Even with small loading, never use a motor whose nameplate amperage exceeds the inverter
rated current.
DANGER
Extreme caution should be used if braking method is set for Decelerate to stop. If deceleration
time is too long, equipment could run into the end stop device, causing damage to equipment
or injury to personnel.
WA R N I N G
Because of the additional potential hazards that are introduced when any drive is operated
locally, we advise you to avoid operating it this way. If the drive is operated locally, be aware
that the crane or hoist will move when the RUN button is pressed. Contact Magnetek with any
questions.
The functions assigned to F1 and F2 vary depending on the current displayed menu. The
1 name of each function appears in the lower half of the display window.
Scrolls up to display the next item, selects parameter numbers, and increments setting
5 values.
Scrolls down to display the previous item, selects parameter numbers, and decrements
6 setting values.
11 Lit while the operator is selected to run the drive (LOCAL mode).
*2 The LO/RE key can only switch between LOCAL and REMOTE when the drive is stopped. To enable the LO/RE key to switch between
LOCAL and REMOTE, set parameter O02-01 to 1.
Before shipping the drive, Magnetek programmed initial settings in the drive’s software so that most,
if not all, of the crane system requirements are supported. However, if it is necessary to change the
initial settings, Magnetek recommends that only qualified crane system technicians program the
drive. This can be accomplished by using the Password and Access Level features. For more
information on these security features, see “Initialization Set-Up” on page 4-9.
The drive can be programmed to allow personnel with limited crane system knowledge to program
only certain parameters, called User Parameters. To select these parameters, see “User
Parameters (A02-01 through 32)” on page 4-16.
Two other features to be aware of are Initialize Parameters (A01-05) and User Defaults (O02-03).
Both of these features are related and revert back to previously saved parameter settings. This is
especially helpful when a number of programming changes were made, but the previous settings
may still be needed. To program these features, see “Initialize Parameters (A01-05)” on page 4-15
and “User Defaults (O02-03)” on page 5-124.
Operation Mode
Programming Mode
Parameter access levels, control method, motion, speed reference, and passwords are selected.
Parameters are set/read. Items to be set/read vary depending on the access level setting.
Auto-Tuning Mode
Automatically calculates and sets motor parameters to optimize drive performance.
Only parameters that have been changed from the factory settings are set/read.
Initialize*
NOTE: An auto-tune should be performed for all Flux Vector and Open Loop Vector applications.
Refer to the Auto-Tuning section on page 4-17.
Motion (A01-03)
Set this parameter to match the motion of application. See X-Press Programming (Table 4-6, 4-7, or
4-8 on pages 4-12, 4-13, and 4-14) for details.
NOTE: Performing a 7770 initialization will clear a parameter set stored in the digital operator.
To create a password, when A01-06 is displayed, press the and key simultaneously
to set A01-07.
The A2 group is pre-loaded with the settings listed in table 4-10, based on A01-03.
A02-05 B03-04: Change Rotation B03-04: Change Rotation B03-04: Change Rotation
A02-06 B05-01: Accel Time 1 B05-01: Accel Time 1 B05-01: Accel Time 1
A02-07 B05-02: Decel Time 1 B05-02: Decel Time 1 B05-02: Decel Time 1
A02-08 C01-03: Reverse Plug C02-01: MicroSpd Gain 1 C01-01: Quick Stop
A02-09 C01-04: Rev-Plg Dec Time C03-01: UL1 Speed C01-02: Quick Stop Time
A02-10 C01-05: Rev-Plg Acc Time C03-04: LL1 Speed C02-01: MicroSpd Gain 1
A02-12 E01-03: V/f Selection C06-02: SwiftLift FWDSpd C03-04: LL1 Speed
A02-13 E02-01: Motor Rated FLA C06-03: SwiftLift REVSpd C06-01: Ultra-Lift
A02-14 H01-06: Terminal S6 Select C06-04: SL FWD Current/Torque C06-02: UltraLift FWDSpd
A02-15 H01-07: Terminal S7 Select C06-05: SL REV Current/Torque C06-03: UltraLift REVSpd
A02-16 H01-08: Terminal S8 Select C06-06: SL Enabling Spd C06-04: UL FWD Torque
A02-17 H02-03: Terminal M5/M6 Select E01-03: V/F Selection C06-05: UL REV Torque
A02-18 H03-02: Terminal A1 Function Select E01-04: Max Frequency C08-03: Min Brk Rel Trq
A02-19 H04-02: Terminal FM Gain E02-01: Motor Rated FLA C08-10: Load Float Time
A02-30 -- -- --
A02-31 -- -- --
A02-32 -- -- --
CAUTION
The brake output is not energized during Auto-Tune. The brake must be manually released
before tuning and set when Auto-Tuning is complete. Ensure no load is on the hook, and that
the hook is near the floor.
The IMPULSE®•G+ & VG+ Series 4 can adapt to nearly all motors manufactured worldwide with its
automatic tuning function. The inverter asks the user for minimal motor information, and then guides
the user through a quick simple tuning process. Ideally, perform a standard Auto-Tune with the motor
uncoupled from the load. When the motor cannot be decoupled, perform a static or non-rotating
Auto-Tune.
NOTE: Contact Magnetek’s service department if an auto-tune can not be performed.
This method requires that the motor be unloaded or decoupled from the load with the brake
disengaged.
The instructions below will provide a step-by-step procedure to complete the non-rotational segment
of this Auto-Tune function:
1. In preparation for the Auto-Tune, the crane should be unloaded with minimal attachments. This
Auto-Tuning method requires free rotation of the unloaded motor, so decoupling the motor from
the load may be necessary.
2. Ensure the break is not set during the Auto-Tuning process.
3. Using the keypad, browse to the “Auto-Tuning” menu.
4. Choose “Standard Tuning” (T01-01 = 0) for the Tuning Mode.
5. Enter the nameplate motor characteristics (T01-02 – T01-08) until the “Tuning Ready?” screen is
reached.
6. Press the green “RUN” key to start the Auto-Tune. It will take up to a few minutes to complete.
During this time, the current will ramp up and down and a high pitched frequency may be audible
coming from the motor; this is normal. The motor will then begin a rotational cycle, which will
complete in one minute or less.
7. When the Auto-Tune has completed, the keypad display will display an “End Tune Successful”
message. Press the “ESC” key twice to exit.
NOTE: If the STOP key is depressed during tuning, auto-tuning is interrupted and the motor
coasts to a stop. The data changed during tuning returns to its original values.
This method will require a short movement of the crane subsequent to the non-rotational Auto-Tune
process which allows the drive to calibrate the Motor Rated Slip and No-Load Current.
The instructions below will provide a step-by-step procedure to complete the non-rotational segment
of this Auto-Tune function:
1. In preparation for the Auto-Tune, the crane should be unloaded with minimal hook attachments.
For Traverse motion, ensure freedom of travel for Step #6.
2. Using the keypad, browse to the “Auto-Tuning” menu.
3. Choose “Tune-No Rotate1” (T01-01 = 1) for the Tuning Mode.
4. Enter the nameplate motor characteristics (T01-02 ~ T01-09) until the “Tuning Ready?” screen is
reached.
5. Press the green “RUN” key to start the Auto-Tune. It will take up to a few minutes to complete.
During this time, the current will ramp up and down and a high pitched frequency may be audible
coming from the motor; this is normal. When the Auto-Tune has completed, the keypad display
will display an “End Tune Successful” message. Press the “ESC” key twice to exit.
6. Run the motor to at least 30% of the Rated Frequency (T01-05). For example, if the Rated
Frequency is 60 Hz, the motor must run to at least 18 Hz. In a hoisting motion, the motor must
be run in the Up/Raising direction.
NOTE: In hoisting motions, remove any loads or spreader bars.
7. When the short run and adjustments have been completed, the motor will stop, and the keypad
will display “TMDN Tune Complete”. The Auto-Tune is now complete and the drive is ready for
normal operation.
This method is recommended for motors configured with the V/f control method when the motor
horsepower and motor rated current are known.
The instructions below will provide a step-by-step procedure to complete the non-rotational segment
of this Auto-Tune function:
1. In preparation for the Auto-Tune, the crane should be unloaded with minimal hook attachments.
2. Using the keypad, browse to the “Auto-Tuning” menu.
3. Choose “Term Resistance” (T01-01 = 2) for the Tuning Mode.
4. Enter the nameplate motor characteristics for Motor Horsepower and Motor Rated Current (T01-
02 and T01-04) until the “Tuning Ready?” screen is reached.
5. Press the green “RUN” key to start the Auto-Tune. It will take up to a few minutes to complete.
During this time, the current will ramp up and down and a high pitched frequency may be audible
coming from the motor; this is normal. When the Auto-Tune has completed, the keypad display
will display an “End Tune Successful” message. Press the “ESC” key twice to exit.
This method is recommended when the motor cannot be decoupled, and the Motor Rated Slip is
known. If the Motor Rated Slip is not known, then the Non-Rotational 1 (T01-01 = 1) is
recommended.
The instructions below will provide a step-by-step procedure to complete the non-rotational segment
of this Auto-Tune function:
1. In preparation for the Auto-Tune, the crane should be unloaded with minimal hook attachments.
2. Using the keypad, browse to the “Auto-Tuning” menu.
3. Choose “Tune-No Rotate2” (T01-01 = 4) for the Tuning Mode.
4. Enter the nameplate motor characteristics (T01-02 ~ T01-10) until the “Tuning Ready?” screen is
reached.
5. Press the green “RUN” key to start the Auto-Tune. It will take up to a few minutes to complete.
During this time, the current will ramp up and down and a high pitched frequency may be audible
coming from the motor; this is normal. When the Auto-Tune has completed, the keypad display
will display an “End Tune Successful” message. Press the “ESC” key twice to exit.
Programming Advanced
Features
This page intentionally left blank.
Application
• B1 Preset References
• B2 Reference Limits
• B3 Sequence/Reference Source
• B5 Acceleration/Deceleration
• B8 Jump Frequencies
Preset Reference
B01-01
On Off Off Off Off Off
Speed Ref 1
B01-02
On On Off Off Off Off
Speed Ref 2
B01-03
On On On Off Off Off
Speed Ref 3
B01-04
On On On On Off Off
Speed Ref 4
B01-05
On On On On On Off
Speed Ref 5
B01-06
On Off On Off Off Off
Speed Ref 6
B01-07
On Off On On Off Off
Speed Ref 7
B01-08
On Off Off On Off Off
Speed Ref 8
B01-09
On Off On On On Off
Speed Ref 9
B01-10
On Off Off On On Off
Speed Ref 10
B01-11
On Off Off Off On Off
Speed Ref 11
B01-12
On On Off Off On Off
Speed Ref 12
B01-13
On On On Off On Off
Speed Ref 13
B01-14
On Off On Off On Off
Speed Ref 14
B01-15
On On Off On Off Off
Speed Ref 15
B01-16
On On Off On On Off
Speed Ref 16
An alternate upper limit frequency can be used during operation when a Multi-Function Digital Input
(MFDI) is set to 59 (Alt F-Ref Up Lmt) and the MFDI is on.
* Initial value is determined by X-Press Programming (Table 4-6, 4-7, or 4-8 on pages 4-12, 4-13, and 4-14).
Run
Command
Brake
Output
Upon run command removal, the motor decelerates to stop. The brake delays for a time interval
(C12-02) before it is set. This option reduces brake wear for applications that involve frequent
stopping and starting.
Zero-Speed Operation
This parameter sets the drive behavior when the frequency reference is below the Zero Speed level.
Jump Frequencies
This function allows the “jumping” of critical frequencies so that the motor can operate without
resonant vibrations caused by some machine systems. This function is also used for deadband
control. Setting the value to 0.0 Hz disables this function.
Field Forcing
The Field Forcing function compensates the delaying influence of the motor time constant when
changing the excitation current reference and improves motor responsiveness. Field Forcing is
ineffective during DC Injection Braking.
C2: Micro-SpeedTM
C3: Klixon
C3: EPLS
C6: Swift-LiftTM/Ultra-LiftTM
C7: Anti-Shock
The VG+ Series 4 Software allows one or more IMPULSE®•VG+ Series 4 driven motors to be
connected in a Master/Slave fashion such that slave inverter will follow the torque reference of the
master inverter. It can be configured in two ways, either as a dedicated Slave or as a Master/Slave
that can be switched on or off by multi-function digital input. When it is in Load Share Mode (Slave),
it is essentially a torque helper to the master motor. The Master outputs the commanded amount of
torque from a ± 10 VDC analog signal into the Slave, which correlates directly to the direction and
quantity of torque the Slave should apply to its own motor. This can be particularly useful when two
or more motors are driving a common load (i.e. single drum, gear box, etc.) and it is important that
they share the load. This will allow one inverter/motor to handle the speed reference and speed
regulation while the others simply help the master. This overcomes inherent problems with having
more than one inverter/motor trying to regulate speed on a common load. The Load Sharing function
can be used when the master is configured for Hoist or Traverse motions (i.e. for a hoist motion, two
or more motors coupled to a single gearbox; for a traverse motion, a circular crane, multiple motors
driving a single end truck, cable reel, etc).
NOTE: The master drive can be an IMPULSE®•VG+ Series 1, 2, 3, or 4.
When using Multi-function digital input H01-0x = 66—”Load Share” (Torque Following mode), setting
C03-11 = Enabled will allow the inverter to accept the Limit Switch inputs where H01-0x = 06–0D.
When C03-11 = Disabled (Factory Default), the Slave will ignore any change in state of the Limit
switch inputs. The setting of this parameter is only in effect when the Multi-function digital input H01-
0x = 66 “Load Share” is ON. It is important to understand that when in Load Sharing mode, the Slave
is only supplying torque to help the Master. The Master typically handles the logic of limit switches or
1. The Master and Slave drives must be set to Flux Vector control method, A01-02 = 3.
2. The Master drive requires a ±10 VDC output with H04-01 or H04-04 = 109 — “Torque Reference”.
3. The Master drive analog output gain (H04-02 or H04-05) should be = 50%.
4. The Master drive requires H02-0x = 2A — “During RUN 2”.
5. The Slave drive requires H01-xx = 66 — “Load Share”.
6. The Slave drive requires a ±10 VDC input with H03-06 or H03-10 = 13 — “Torque Reference”.
7. The Slave drive analog input gain (H03-07 or H03-11) should be = 200%.
8. OPTIONAL: The Master drive can be set to H01-xx = 68 — “LodShr Ready Run”, and then the
Slave Drive can be set to H02-0x = 0 — “Brake Release.”
Klixon
The Klixon Multi-Function input is intended for motors that have a Motor Thermal Overload Switch.
Klixon is usually embedded in the motor windings and changes state when the motor reaches a
certain temperature. When a multi-function input (H01-0x = 56 or 57) is active, the drive will use the
stopping method programmed in C03-12 and display the KLX Klixon alarm. The drive will resume
normal operation when the motor cools down and a new RUN command is applied.
DANGER
Load Check II is designed to limit loads less than or equal to the crane’s rated capacity.
Consult the factory and crane manufacturer before calibrating Load Check II with a load
heavier than the crane capacity.
Swift-Lift
Swift-Lift can be enabled in the Standard Hoist motion of the G+ Series 4. In the V/f control method,
the Swift-Lift function uses motor current to determine the maximum safe speed. When the OLV
control method is selected, the Swift-Lift function uses motor torque in place of motor current for its
safe speed calculations. Swift-Lift will not be enabled if the current or torque levels exceed C06-04 or
C06-05 settings. Both C06-04 and C06-05 are a percentage of E02-01.
Ultra-Lift
Ultra-Lift can be enabled in the Non-mechanical Load Brake (NLB) Hoist motion of the VG+ Series 4
(FLV only). The Ultra-Lift function measures motor torque at base speed and then accelerates to the
maximum safe speed. Ultra-Lift will not be enabled if the torque levels exceed C06-04 or C06-05
settings.
Adaptive Ultra-Lift
Adaptive Ultra-Lift can only be enabled in the (NLB) Hoist motion of the VG+ Series 4. The Adaptive
Ultra-Lift function continuously monitors motor torque when running above base speed to increase
or decrease motor speed based on varying load conditions.
NOTE: Ultra-Lift is disabled when in traverse applications. Maximum Frequency (E01-04) must be
> C06-02 and C06-03.
0 Disabled
1 Enabled Auto
2 Enabled by MFDI
3 Enabled Adaptive Flux Vector NLB only
4 Adaptive by MFDI Flux Vector NLB only
C06-02 SwiftLift FWDSpd (V/f and Maximum Swift-Lift Forward 0.1–150.0 Hz 60.0 G+/VG+
OLV) Speed
UltraLift FWDSpd (FLV)
C06-03 SwiftLift REVSpd (V/f and Maximum Swift-Lift Reverse 0.1–150.0 Hz 60.0 G+/VG+
OLV) Speed
UltraLift REVSpd (FLV)
C06-04 SL FWD Current (V/f) Output Current/Torque < C06- 0–100% 50 G+/VG+
SL FWD Torque (OLV) 04 to enable Swift-Lift Forward.
Not used with Adaptive UL.
UL FWD Torque (FLV)
NOTE: C06-11 through C06-16 are hidden unless C06-10 is set to “Custom”. Otherwise, C06-11
through C06-14 are automatically modified by C06-10.
WA R N I N G
Motors and drive machinery must be capable of operating above motor base speed. Consult
the motor/gearbox/hoist manufacturer before enabling the Swift-Lift and Ultra-Lift function.
Failure to observe this warning may result in damage to equipment and possible injury or
death to personnel.
This traverse torque limiter function (C07-10 and C07-11) is used in multi-drive, closed-loop traverse
applications to reduce drive fighting due to speed discrepancies between the two sides of a bridge.
This resolves the situation where one side of a bridge will be at full forward torque, while the other
side is a full regen torque. When moving below the Limiter Freq, this feature is disabled and the drive
behaves as normal. When accelerating past the Limiter Freq, the ASR I time is reduced to zero to
limit torque imbalance. Once the motor has accelerated to within the Limiter Freq (i.e. 60 Hz) the
regen torque limit also goes to zero. The drive will remain in this state until the speed reference is
changed. When the speed reference is raised or lowered, regen torque is re-enabled to accel or
decel the bridge as required.
Note that a heavy swinging load may pull the bridge faster than the PG Overspeed level. It is
therefore highly suggested that a PG Overspeed Sel (F01-23) be set to Alarm Only.
To make Anti-Shock less sensitive to light loads and more sensitive to heavy loads:
1. Increasing C07-15 (Torque Delta) to a higher percentage increases the torque spike magnitude
that is required to trigger Anti-Shock.
2. Increasing C07-16 (Detection Time) to a higher time widens the window of time that a torque
spike is looked for.
Troubleshooting
Cause: This is caused by a torque increase due to acceleration, which falls within the parameter
settings for triggering Anti-Shock.
Corrective Action:
1. Increasing C07-14 (Re-Accel Delay) to a higher time may help remedy this occurrence.
2. Increasing C07-15 (Torque Delta) and decreasing C07-16 (Detection Time) will require a higher
torque spike to occur in a shorter amount of time.
Cause: By default, Anti-Shock is configured to decelerate very quickly when a torque increase is
detected. The deceleration rate may cause a rapid increase in voltage or current, which may fault the
drive.
Corrective Action:
1. Increasing C07-18 (Smoothing Decel) will increase the time it takes for the drive to decelerate
directly after the torque spike is detected. Spikes in voltage and/or current will be reduced.
Start
The start sequence begins by building up torque in the motor to a predefined level within the C08-01
(Torque Compensation Time) timer. This level is determined by several factors which are defined
below. During the C08-02 time, the drive is monitoring current to motor. The current feedback
equation must be satisfied within the time set in C08-02 (IFB OK Time). If it is not, a BE2 (No-
Current) fault will be displayed on the keypad and the drive will stop outputting voltage to the motor.
The brake will remain closed.
Once the brake has been commanded to release, the drive output remains in Load Float for the
amount of time programmed into C08-04. During C08-04, the drive waits for the brake to completely
open and watches encoder feedback. If the amount of feedback is less than the setting in C08-05
(Roll Back Count), then the drive proceeds to the BE3 check. If it is not, a BE1 fault is displayed on
the keypad and the sequence stops. For the BE3 check, if the brake opened mechanically, then the
encoder feedback must be greater than or equal to the value programmed in C08-07 (BE3 Detect
Count) within the time set in C08-06 (BE3/Alt Torq Tim). If it is not, then a BE3 fault is displayed. By
the time the drive has completed the BE3 check, there should be a significant amount of motor shaft
movement and the start sequence is complete.
Stop
The stop sequence begins when the run command has been removed and the output frequency has
decelerated to zero. Once at zero speed, the motor maintains a Load Float position for the duration
of C08-10 (Load Float Time). During the Load Float time, run commands in either direction are
accepted and will begin accelerating immediately in the commanded direction, thereby skipping the
start sequence entirely. The Load Float Timer is reset after each new run command. Once the Load
Float Timer expires, the brake output command is removed (thereby closing the brake) and Load
Float is maintained for the time set in C08-11 (Brake Set Delay) to allow the brake to fully close.
Once the Brake Delay Time has expired, the BE6 check is executed. The BE6 check monitors
encoder feedback while the load is being transferred from the motor to the brake and compares it to
C08-13 (BE6 Max Count). The encoder feedback must not exceed the number of counts in C08-13
within the C08-12 (BE6 Detect Timer) time. If it does (meaning the load slipped through the brake), a
BE6 alarm is displayed on the keypad and the drive will reset its Load Float position and maintain its
new position. Run commands will still be accepted with the exception of a reduced speed in the up
direction set by C08-18 (BE6 Up Speed Limit) and the NLB stop sequence will begin again once the
run command had been removed.
Torque Proving
Factor 1: On the first run command after power up, or after any major fault which causes the stop
sequence to be skipped, the start sequence by default uses the value programmed in C08-16, the
Initial Brake Release torque.
Factor 2: Once the system has completed a successful start and stop, a new Brake Release Torque
value is used. This value is one that has been memorized and stored into memory during the stop
sequence. It is equivalent to the amount of torque required for the motor to hold the load on the hook
in Load Float with the brake released. Some benefits of stored Load Float torque for the next brake
release are:
• Faster response to run commands when drive is in Base Block Status.
• Upon brake release, shaft rotation begins in the direction of the run command.
The Dual Brake feature is designed for hoist systems with redundant holding brakes. One brake is
controlled by an MFDO programmed to 00, and the second brake is controlled by an MFDO
programmed to 0A. After a Load Float, during the BE6 (Brake Test) time, one brake is left Open,
while the drive tests that the Closed brake is capable of holding the load. After the BE6 time expires,
the second brake is closed.
This feature is only intended as a method to test each brake individually. A mechanical delay system
may be required to prevent both brakes from closing simultaneously if power is lost.
NOTE: All brake faults are annunciated by both the keypad and via a programmed digital
output. Since the keypad is not visible by the operator, an external warning device must be
used to ensure proper safety of personnel and equipment. Annunciating a brake fault can be
accomplished by using one, or both, of the following methods: 1) An indicator or strobe light
that is continuously “ON”, indicating proper operation. If the light should turn “OFF”, this
indicates that the light bulb has either burned out, or there is a drive or brake problem. Either
scenario requires immediate corrective action. 2) The use of an indicating light wired to relay
output terminals MC-MA, N.O. contact, or an audible warning device that will sound during a
brake fault condition. A 120 VAC audible warning device can be wired directly to terminals
MC-MA, provided that its ratings do not exceed the 1 Amp, 120 VAC, Inductive Spec.
If a brake fault is annunciated during a “Start” sequence, it is recommended that the crane be
moved to a safe location with the load on the hook. The hoist should only be operated if
absolutely necessary. In this type of alarm sequence, either the brake is seized or the drive
cannot develop enough torque in the motor in the time allotted. To troubleshoot the hoist, it
will be necessary to monitor the keypad on the drive and operate the hoist at the same time.
Two people are recommended for this procedure. With one person operating the hoist and
the other person monitoring the keypad, run the hoist. The keypad should display one of the
following faults: BE1, BE2, BE3, or BE4. For corrective action, refer to “Troubleshooting the
Drive” in Chapter 6 of this manual.
If a brake fault is annunciated after the hoist has come to a complete stop, and Load Float
(C08-10) has timed out, it would indicate that the drive has checked the brake and determined
that the brake has insufficient torque available to hold the load. DO NOT TURN OFF POWER.
This condition indicates that the brake has failed and the drive / motor combination is
suspending the load. If, during this condition, the hoist is operated in the “Raise” direction, it
will only be allowed to run at a speed equal to or less than the “BE6 Up Speed” setting in
parameter C08-18 (C08-18 is 6 Hz by default.) This is an additional indication that the brake
has failed to open, or the load is slipping through the brake. It is recommended that the crane
be moved to a safe location and the load lowered to the ground. Corrective action should be
taken to repair the brake. The keypad will be displaying one of two alarms during this
condition: BE5 or BE6. Refer to “Troubleshooting the Drive” in Chapter 6 of this manual.
WA R N I N G
DO NOT turn off power to the drive during a BE6 or BE8 alarm. This may result in loss of
control of the load if the brake has failed in the open position or is unable to hold the load.
**
**
During a BE5, BE6, or BE8 alarm, power should not be removed from the drive. The load
should be lowered to the ground and the crane moved to a safe location for service.
E-Lift (VG+)
The E-Lift (Emergency Lift) function can be utilized to operate the drive in the event of an encoder
related fault (PGO-1-S/PGO-1-H) that resulted from a defective encoder, encoder cable, or PG-X3
option card. E-Lift can be enabled with a Multi-Function Input (H01-01 ~ H01-08 = 44) under the
condition that all run commands have been removed and the drive is not outputting voltage.
When E-Lift is active, the drive will switch to the control method set in E03-01. In hoist applications, it
is highly recommended to leave E03-01 set to OLV, which will ensure the proper control of the load.
Furthermore, all functions that depend on encoder feedback will be disabled. The Test Mode
Configuration parameters (E03-xx group) are active during E-Lift operation instead of the E01-xx
parameters. By default, the E-Lift function may only remain operational for 10 minutes (user-
adjustable by C08-37), after which a fault will be generated.
DANGER
E-Lift is designed to allow for temporary hoisting operations of motors normally equipped with
an encoder in Flux Vector control. Always follow instructions given in the E-Lift setup
instructions, and utilize extreme caution when operating a hoist in E-Lift mode. Stop the hoist if
any undesired motion occurs and contact Magnetek for additional assistance.
DANGER
Do NOT set E03-01 to a value of 0 (V/f Control) when using E-Lift in hoist applications. E-Lift is
designed to operate using the Open Loop Vector (OLV) control method. The use of the V/f
control method may cause undesired motion of the load and is only intended for
troubleshooting Flux Vector Control method related problems.
DANGER
If any undesired motions occur while E-Lift is active, immediately remove any RUN
commands, turn off the E-Lift MFDI, and contact Magnetek.
f. If steps 4.a through 4.e were successful, turn off the E-Lift MFDI and return the hoist to
normal operations.
Terminal Designation
Parameter Display Range** Default
DI-A3 S4I S4IO
C09-02* DIO Terminal 1 0 I1 I1 00–FF 0F
C09-03* DIO Terminal 2 1 I2 I2 00–FF 0F
C09-04* DIO Terminal 3 2 I3 I3 00–FF 0F
C09-05* DIO Terminal 4 3 I4 I4 00–FF 0F
C09-06* DIO Terminal 5 4 -- -- 00–FF 0F
C09-07* DIO Terminal 6 5 -- -- 00–FF 0F
C09-08* DIO Terminal 7 6 -- -- 00–FF 0F
C09-09* DIO Terminal 8 7 -- -- 00–FF 0F
C09-10* DIO Terminal 9 8 -- -- 00–FF 0F
C09-11* DIO Terminal 10 9 -- -- 00–FF 0F
C09-12* DIO Terminal 11 A -- -- 00–FF 0F
C09-13* DIO Terminal 12 B -- -- 00–FF 0F
C09-14* DIO Terminal 13 C -- -- 00–FF 0F
C09-15* DIO Terminal 14 D -- -- 00–FF 0F
C09-16* DIO Terminal 15 E -- -- 00–FF 0F
C09-17* DIO Terminal 16 F -- -- 00–FF 0F
* See Table 5-72 for MFDI selections. The following input functions will not operate on an input option board: 20~20F, 31, 34, 35, 47, 80,
or 81.
NOTE: Weight Calculations will be more consistent when a weight measurement is calculated
at the same speed every time. Example: C10-01 = 1, weight measurement is always
calculated at C10-05 speed. It is important to note that after the load has been rigged,
it should be suspended and the brakes should be set on the hoist. When the next
raise command is given, the hoist is now ready to calculate the weight of the load. The
function only works in the Raising motion (Fwd Run). If extreme accuracy is required,
a load cell should be used.
The Weight Measurement function of the hoist drive has an accuracy within 5% with
VG+ drives and 10% with G+ drives of the hoist’s rated capacity.
The Slack Cable Detection is not executed, unless both of the following conditions are true:
• The output frequency is between C11-04 and C11-06.
• The Slack Cable Detection delay time is between C11-05 and C11-07.
Setup Procedure:
• Set the Slack Cable Detection torque level (C11-03), by lowering the hoist without load
at a constant speed that the hoist would normally run during the operation. Monitor
and record the torque reference (U01-09). Repeat the above operation several times
to ensure an accurate reading.
• Then set C11-03 = [(U01-09)-2].
• Enable Slack Cable Detection by setting the C11-01 to 1.
• Select output action when Slack Cable is detected by defining C11-02.
Set Up
Parameter U01-30 should be monitored during operation to obtain the exact speed difference in Hz
between the two shafts. The low speed shaft speed is normalized internally by multiplying the speed
of the gear ratio. The value of C11-12 should be adjusted at start up such that U01-30 approaches
0.0.
Jog or Run
Command
Frequency
Output
Delay Delay
Brake
Command
Load Share
Please refer to page 5-20 for more information on Load Share.
CAUTION
A directional input is not needed to enable motor torque.
The total distance (Pulses) the motor will index is determined by the following equation:
When the Index function is turned ON, the function can also be programmed to repeat an Index as
long as the Run command is enabled and by setting the Index Repeat Delay (C13-06) greater than
0.00 seconds. The Index will repeat again after the Index Repeat Delay (C13-06) time has expired.
Once the motor completes the Index, the brake will either set or remain in Load Float depending on
the braking sequence described below.
When an Index move is complete, a Multi-Function Output (Index Complete H02-xx = 34) can be
programmed to turn ON, and will remain ON until one of the following is true:
• another directional run input is received,
• the repeat delay time has expired and the movement is repeating, or
• the Index Function is disabled.
When the Index Function is turned ON in Traverse applications, the Index Brake Control (C13-12)
can control the action of the brake. The following describes the brake control for each setting:
When the Index Function is turned ON, the brake will release and hold the position in Load Float
until a run command is applied. The brake will set and normal operation will resume when the
Indexing function is disabled.
When the Index function is turned ON, the brake will release after each run command is applied,
then Index the motor. The brake will set after the Index or Index Repeat is complete, or the run
command is removed.
When the Index function is turned ON, the brake will release when a run command is applied, then
the drive will Index the motor and will hold the position in Load Float after the Index function is
complete. The drive will remain in Load Float until another run command or the Index function is
turned OFF. The brake will set and normal operation will resume when the Index function is turned
OFF.
NOTE: For best performance, enable Index after brake has released. Not recommended for
double A4 applications.
When the motion is No-Load Brake Hoist and the Index Brake Control C13-12 = 2, the action of the
brake is controlled by the No-Load Brake sequence. The Index function can be enabled at any time
during operation and the action of the brake is described below in C13-12.
At Stop
If the Index function is turned ON while the crane is stopped, the brake will release when a run
command is applied. Then the drive will Index the motor and will hold the position in Load Float after
the Index function is complete. The drive will remain in Load Float until another Run command is
applied or the Index function is turned OFF. When the Index function is turned OFF, the drive will set
the brake according to the No-Load Brake stop sequence.
During Run
If the motor is in motion when the Index function is turned ON, the drive will decelerate to zero and
hold the position in Load Float. After a Run command is applied, the drive will Index the load and
hold the position in Load Float after the Index is complete. The brake is set according to the No-Load
Brake stop sequence when the Index function is turned OFF.
NOTE: For best performance, enable Index after brake has released. Not recommended for
double A4 applications.
NOTE: When either the Index Enable or Run Command is removed, the stop sequence will be
initiated.
C13-06 Index Rpt Delay Index Repeat Delay Time (Setting 0.00–60.00 0.00 VG+
of 0.00 disables Index Repeat). sec
C13-07 Index Complete Index Complete Width 0–32767 10 VG+
(Quadrupled) for MFDO = 34.
Upper Limit range is dependent on
the following conditions: 32767 or
(C13-04 *4 * PG constant PPR +
C13-05 -1), whichever is smaller.
1 pulse = 1 ppr of F01-01
C13-08 Index Zsv Gain Index Zero Servo Gain. 0–100 10 VG+
C13-09 Index ASR P Gain Index ASR P Gain. 0.00–300.00 30.00 VG+
C13-10 Index ASR I Time Index ASR Integral Time. 0.000–10.000 0.200 VG+
sec
C13-11 Acc/Dec Gain Index Accel/Decel Rate Gain. 0.0–5.0 1.0 VG+
** If both C13-04 and C13-05 = 0, the Index function is disabled.
DC Injection
With decel to stop enabled (B03-03=0), upon removal of the run command, the IMPULSE®•G+ and
VG+ Series 4 drive controls motor deceleration according to the Decel Time setting (B05-02), until
output frequency reaches the DC Injection Braking Start Frequency (D01-01 setting). Then the
IMPULSE®•G+ and VG+ Series 4 frequency output is turned off and DC injection current is applied
to the motor. The effective DC injection time and current should be set to provide adequate stopping
without excessive motor heating. The DC injection voltage is determined by the DC injection braking
current and motor impedance.
Torque Compensation
The motor torque requirement changes according to load conditions. Full-range automatic torque
boost adjusts the voltage of the V/f pattern according to the required torque. The IMPULSE®•G+ and
VG+ Series 4 automatically adjusts the voltage during constant-speed operation as well as during
acceleration.
The required torque is calculated by the inverter. This ensures trip-less operation and power
savings.
When more torque is needed, increase the torque compensation gain in one-tenth (0.1) increments.
Increase the setting when the wiring distance between the inverter and the motor is 100ft. or longer.
If the motor generates excessive vibration or oscillates, decrease the torque compensation.
Increasing torque compensation gain increases motor torque, but an excessive increase may cause
the following:
• Inverter fault trips due to motor overexcitation, and/or
• Motor overheat or excessive vibration.
Generally when tuning the ASR, optimize the ASR gain before adjusting the integral time settings.
Always make adjustments with the load connected to the motor.
The drive is preset to use ASR settings D04-01/02 over the entire speed range in FLV. If required by
the application, a second set of ASR parameters (D04-03/04) can be automatically activated
depending on the motor speed or by using a digital input. Refer to the description in D04-01/D04-02
and D04-03/D04-04 on page 5-59.
Alternatively, use different ASR settings for high and low speed. Set the values from step 1 and 2 to
parameters D04-03 and D04-04, then set an ASR switching frequency in parameter D04-07. Run the
motor at a speed higher than D04-07 and repeat step 3 while adjusting D04-01 and D04-02.
These parameter settings will function differently depending on the control method.
NOTE: Mechanical backlash in an application can cause secondary current (I2) reference
variations in the motor’s rotor. This condition can prevent the desired adjustment of ASR
parameters. The output delay time constant is used to increase the stability of the system
allowing a wider setting range of ASR parameters.
Parameters D04-03 and D04-04 define the ASR proportional gain an integral time at zero speed.
The settings in D04-01 and D04-02 are used at speeds above the setting in D04-07. D04-07 is set
by default to 0.0 so D04-01 and D04-02 are used by default over the entire speed range. However,
changing D04-07 creates two levels of ASR control settings, as shown in Figure 5-19 below.
This function is used to avoid excessive changes in torque, which may be caused by abnormal
resonance when the torque reference changes rapidly.
NOTE: Speed/torque control selection can also be made by using a multi-function input select
(H01-xx = 34 speed-torque control changeover).
The figure below shows FWD/REV run switching during deceleration to stop. The S-curve function
will add time to the acceleration and deceleration. Time to accelerate from the minimum frequency to
the maximum frequency (total acceleration) is:
Total Acceleration =
Time to decelerate from the maximum frequency to the minimum frequency (total deceleration) is:
Total Deceleration =
CAUTION
CAUTION
Consult Magnetek for drive derating before modifying the D10 group
parameters. Failure to do so may result in equipment damage.
Increase the set value of D11-02 when hunting is present while driving a light load. Decrease the set
value of D11-02 when the motor vibrates or stalls while driving a heavy load.
Voltage/Frequency Pattern
WA R N I N G
Drive input voltage (not motor voltage) must be set in E01-01 for the protective features of the
drive to function properly. Failure to do so may result in equipment damage and/or death or
personal injury.
An OPE10 error will occur if the following conditions are not met:
The setting E01-01 sets the maximum and base voltage used by preset V/f patterns (E01-03 = 0 to
E), and adjusts the levels of drive protective features (e.g. Overvoltage, braking resistor turn-on, stall
prevention, etc).
Euro (V/f) F
50.0 200.0 50.0 2.5 17.0 1.3 11.0 0 0 0
& FF
US (OLV) F
60.0 230.0 60.0 3.0 13.8 0.5 2.9 0 0 0
& FF
Euro (OLV)
50.0 200.0 50.0 2.5 12.0 0.5 2.5 0 0 0
F& FF
* Default for O02.09 = 1 and not Std Hoist
*1 Default for O02.09 = 1 and Std Hoist
*2 Default for O02.09 = 2 and not Std Hoist
*3 Default for O02.09 = 2 and Std Hoist
If rotational auto-tuning cannot be performed, E02-02 and E02-05 can be calculated using the
motor’s nameplate information or by performing non-rotational auto-tuning.
Motor rated slip frequency (E02-02) can be calculated by using the following equation:
fs f
N * P
120
W h ere… fs: slip freq uency (H z)
f: rated frequency (H z)
N: rated m otor speed (rpm )
P: num ber of m otor poles
Motor terminal resistance E02-05 can be calculated by using the following equation:
25 C Ti
273
rt r p * 2
2 73 Ti
W here… r t : m oto r t erm inal resistance
r p : Phase-to-P hase resistance at insu lation class tem perature
T i : insulation class tem peratu re (°C )
When the 3CH individual input is used, parameter B03-01 is automatically set to “1” (frequency
reference from control circuit terminal). The option/inverter reference selection, which is selected by
a multi-function digital input (H01-xx= “1F”), is disabled when using the AI-A3 option.
Table 5-68: DO-A3 Output Mode Selection for IMPULSE®•G+ and VG+ Series 4
Parameter Output
F05-09 Terminals Output Contents
Type
setting
TD5 – TD11 OverCurrent (SC, OC, GF)
TD6 – TD11 OverVoltage (OV)
TD7 – TD11 Drive Overload (OL2, OH, OH1)
8 –Channel
Individual TD8 – TD11 Fuse Blown (PUF)
0 (Fixed TD9 – TD11 OverSpeed (OS-1, OS-2)
Data)
TD10 – TD11 Motor Overload (OL1)
TD1 – TD2 Brake Release
TD3 – TD4 Limit Switch (UL1, UL2, UL3, LL1, or LL2)
Bit 3, 2, 1, 0 Output Bit 3, 2, 1, 0 Output
TD5 – TD11 0000 No Fault 1000 EF (ALL)
(Bit 0)
0001 SC, OC, GF 1001 CPF (ALL)
0010 OV 1010 oL1
TD6 – TD11 0011 OL2 1011 BE7
(Bit 1)
0100 OH, OH1 1100 UV (ALL)
0101 OS-1, OS-2 1101 DEV-1, DEV-2
TD7 – TD11 PGO-1-S
Binary (Bit 2)
1 Coded PGO-1-H
0110 PUF 1110
PGO-2-S
TD8 – TD11 PGO-2-H
(Bit 3)
0111 LF 1111 Not Used
TD9 – TD11 Minor Fault (Alarm)
TD10 – TD11 Inverter Ready
TD1 – TD2 Brake Release
TD3 – TD4 Limit Switch (UL1, UL2, UL3, LL1, or LL2)
TD5 – TD11 F05-01 (See Table 5-76 for output selections)
TD6 – TD11 F05-02 (See Table 5-76 for output selections)
TD7 – TD11 F05-03 (See Table 5-76 for output selections)
8-Channel TD8 – TD11 F05-04 (See Table 5-76 for output selections)
2 Selectable TD9 – TD11 F05-05 (See Table 5-76 for output selections)
TD10 – TD11 F05-06 (See Table 5-76 for output selections)
TD1 – TD2 F05-07 (See Table 5-76 for output selections)
TD3 – TD4 F05-08 (See Table 5-76 for output selections)
Digital Inputs
The IMPULSE®•G+ and VG+ Series 4 has eight multi-function digital inputs for the set-up of
numerous functions. The following table lists the function selections for the multi-function digital
inputs (terminals S1 to S8) and indicates the control methods during which each function can be
enabled. An OPE03 error will occur if a function is programmed in more than one terminal at the
same time.
Table 5-72: Multi-Function Digital Inputs (MFDI) selectable for H01-0x and C09-0x
Display Function
0 Multi-Step Ref 2 Multi-Step Reference 2
1 Multi-Step Ref 3 Multi-Step Reference 3
2 Multi-Step Ref 4 Multi-Step Reference 4
3 Multi-Step Ref 5 Multi-Step Reference 5
4 Speed Hold 2 Speed Hold 2 (2nd Step of Three-Step Infinitely Variable)
5 Accel Command Accel Command (2nd Step of Two-Step Infinitely Variable or 3rd Step of
Three-Step Infinitely Variable)
6 Upper Lmt 1 N.O. Upper Limit - Slow Down; Normally Open. UL1 - blinking
7 Upper Lmt 2 N.O. Upper Limit - Stop; Normally Open. UL2 - blinking
8 Lower Lmt 1 N.O. Lower Limit - Slow Down; Normally Open. LL1 - blinking
9 Lower Lmt 2 N.O. Lower Limit - Stop; Normally Open. LL2 - blinking
Table 5-74: F1 and F2 keys function selectable for H01-09 and H01-10
Display Function Instruction Alert/Confirm Message
0F Not Used No function - -- --
terminal is disabled
48 Flt Latch Reset When a fault is Press F1 or F2 once to pre- Confirm?
latched, toggle this start Fault Latch Reset. A Flt Latch Reset
input ON and then confirm message will appear,
OFF to clear the and the same key press will
fault. be required once more to
reset a latched fault.
53 Comm Test Mode Communication Test Hold down the F1 or F2 key Running:
Mode - loopback test for 2–3 seconds to initiate the Comm Test Mode
of Modbus RS-422/ Comm Test.
485 interface
5A MaintenanceReset Resets Maintenance Press F1 or F2 once to pre- Confirm?
Timer (C12-05, C12- start Maintenance Timer MaintenanceReset
06, U01-52) Reset. A confirm message will
appear, and the same key
press will be required once
more to reset the
Maintenance Timer.
61 Brake Test Motor pushes Hold down the F1 or F2 key to Running:
against brake up to initiate the Brake Test. Brake Test
programmable
torque setting C08-
24 at programmable
frequency C08-25.
Disabled PG Faults
during this condition.
67 Hook Height Home Used with C03-14 - Press F1 or F2 once to pre- Confirm?
Height Measurement start Hook Height Home. A Hook Height Home
function. confirm message will appear,
and the same key press will
be required once more to
home the Hook Height.
69 LC Bypass N.O. Disables Load Hold down the F1 or F2 key to Running:
Check and clears initiate the LC Bypass. LC Bypass N.O.
any LC faults.
73 LL2/UL2 Bypass Bypass Limit MFDI Hold down the F1/F2 key to Running:
and EPLS initiate LL2/UL2 Bypass. LL2/UL2 Bypass
74 LL/UL Bypass Bypass MFDI and Hold down the F1/F2 key to Running:
EPLS initiate LL/UL Bypass. LL/UL Bypass
Table 5-76: Multi-Function Digital Outputs (MFDO) selectable for H02-0x and F05-0x
Display Function
0 Brake Release* ON/CLOSED: When the drive is commanding the brake to be Open
OFF/OPEN: When the drive is commanding the brake to be Closed
1 Zero Speed* ON/CLOSED: When Motor Speed < D01-01 or E01-09
2 Fref/Fout ON/CLOSED: When the output frequency (U01-02) is within the frequency reference
Agree1 (U01-01) ± L04-02
OFF/OPEN: When the output frequency or motor speed is not within the frequency
reference (U01-01) ± L04-02
3 Fref/Set Agree 1 ON/CLOSED: When the output frequency (U01-02) is within L04-01 ± L04-02
OFF/OPEN: When the output frequency (U01-02) is not within L04-01 ± L04-02
4 Freq Detect 1 See the “Frequency Detect” section on page 5-109.
5 Freq Detect 2 See the “Frequency Detect” section on page 5-109.
6 Inverter Ready* ON/CLOSED: After the drive has performed initialization process and no faults or
programming mode is detected
7 DC Bus ON/CLOSED: When the DC Bus voltage falls below the trip level set in L02-05
Undervolt*
8 BaseBlock ON/CLOSED: During BaseBlock - No Voltage output
OFF/OPEN: When drive is not in a BaseBlock state - Voltage Output
9 Operator Ref ON/CLOSED: When frequency reference is from the operator
OFF/OPEN: When frequency reference is not from the operator (i.e. external terminals)
A Brake 2 ON/CLOSED: When the drive is commanding the secondary brake to be Open
OFF/OPEN: When the drive is commanding the secondary brake to be Closed
B Trq Det 1 N.O. ON/CLOSED: When the output current/torque exceeds the value set in parameter L06-
02 for longer than the time set in parameter L06-03.
OFF/OPEN: When the output current/torque does not exceed the value set in
parameter L06-02 for longer than the time set in parameter L06-03.
* This output does not have an inverse output
** Contact will open when power is disconnected
Before you start to program this feature, you may find it convenient to first photocopy the “Binary-to-
Hexadecimal Conversion Worksheet” in this section. By being able to write in the worksheet’s boxes,
you will find it easier to program the feature.
Programming Digital Outputs—Fault Annunciate requires that you determine two 4-digit binary
numbers and then convert these numbers to two 1-digit hexadecimal numbers. You enter the
hexadecimal numbers when you program the drive.
2. Determine the output terminal to which you want Fault Annunciate assigned; Terminals M0-M1,
M2-M3 or M5-M6 and press until the value blinks.
5. From the worksheet in table 5-77, select one of three fault output sets (each row is a set). Enter
the one-zero combination that corresponds to the set (row) that you selected.
6. Determine which fault outputs should be enabled. To enable a fault output, enter 1 in the box
above the fault output; otherwise, enter 0. Do this for each fault output in the set.
7. Using the Binary to Hexadecimal Conversion chart (table 5-79), determine the 1-digit
hexadecimal number for both 4-digit binary numbers.
8. Press the or and buttons until the appropriate hexadecimal number appears
and press Enter.
Example: Select a fault annunciate set in which the fault you want to appear is shown. You must
select only faults from one set. If you want to have the relay output to change based on only inputs
LL1 and UL1, you would choose Set 2.
1. Place a “1” below LL1 and UL1 for Set 2.
2. Use table 5-78 to convert the left binary value “1 0 0 0” to Hex 8.
3. Use table 5-78 to convert the right binary value “1 0 1 0” to Hex A.
4. Enter this value into H02-xx.
First digit from the left Second digit from the left
1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0
First digit from the left Second digit from the left
1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0
First digit from the left Second digit from the left
1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0
First digit from the left Second digit from the left
1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0
Table 5-82: Option Selections for H03-02, H03-06, and H03-10 (Flux Vector)
Display Function
0 Analog Freq Ref1 Analog Frequency reference 1
10V = E01-04 (Maximum output frequency)
1 Frequency Gain The value of the analog frequency reference will be multiplied with the
analog frequency reference gain value.
2 Analog Freq Ref2 Analog Frequency reference 2
10V = E01-04 (Maximum output frequency)
3 Analog Freq Ref3 Analog Frequency reference 3
10V = E01-04 (Maximum output frequency)
5 Acc/Dec T Reduct 10V = 100%
7 OT / UT Det Lvl Motor rated torque (vector control); inverter rated current (V/f control)
9 Ref Lower Limit Max. output frequency
10V = E01-04 (Maximum output frequency)
D Freq Ref Bias 2 The input value of an analog input set to this function will be added to the
frequency reference. This function can be used with any frequency
reference source.
E MotorTemperature
10 FWD Torque Limit Torque limit when motoring in the forward direction.
11 REV Torque Limit Torque limit when motoring in the reverse direction.
12 Regen Torque Limit Torque limit during regen.
13 Torque Reference Torque reference when in Torque Control mode; Torque limit when in
Speed Control mode.
14 Torque Comp
15 Torque Limit Torque limit when motoring.
16 Load Cell Used for Weight Measurement and/or Load Check
1F Not Used --
NOTE: After initial communication, if the inverter is not communicated with for 2 seconds, a
communication fault will occur (CE Memobus ERR).
Motor Overload
The IMPULSE®•G+ and VG+ Series 4 drive has an electronic overload protection function (OL1) for
protecting the motor from overheating. The drive bases the protection on time, output current, and
output frequency. The electronic thermal overload function is UL-recognized, so an external thermal
overload relay is not required for single motor operation.
This parameter selects the motor overload curve used according to the type of motor applied.
Setting L01-01 = 1 selects a motor with limited cooling capability below rated (base) speed when
running at 100% load. The OL1 function derates the motor any time it is running below base speed.
Setting L01-01 = 2 selects a motor capable of cooling itself at any speed when running at 100% load.
The OL1 function derates the motor when it is running at 1/10 of its rated speed or less.
Setting L01-01 = 3 selects a motor capable of cooling itself at any speed when running at 100% load.
This includes zero speed. The OL1 function does not derate the motor at any speed.
If the drive is connected to a single motor, the motor overload protection should be enabled
(L01-01 = 1, 2, 3) unless another means of preventing motor thermal overload is provided. When the
electronic thermal overload function is activated, an OL1 fault occurs, shutting OFF the drive’s
output, thus preventing additional overheating of the motor. The motor temperature is continuously
calculated as long as the drive is powered up.
When operating several motors with one drive, install a thermal relay on each motor and disable the
motor overload protection (L01-01 = 0).
Speed Agree 1
• When enabled using MFDO "H02-xx = 2", the contact closes when the output frequency (U01-
02) is equal to the frequency reference (U01-01) plus or minus the speed agree detection width
(L04-02).
• U01-02 = (U01-01 ± L04-02)
• When enabled using MFDO “H02-xx =3”, the contact closes when the output frequency (U01-
02) is equal to the speed agree detection level (L04-01) plus or minus the speed agree detection
width (L04-02).
• U01-02 = (L04-01 ± L04-02)
Speed Agree 2
• When enabled using MFDO “H02-xx = 13”, the contact closes when the output frequency (U01-
02) is equal to the frequency reference (U01-01) plus or minus the speed agree detection width
(L04-04).
• U01-02 = (U01-01 ± L04-04)
• When enabled using MFDO “H02-xx = 14”, the contact closes when output frequency (U01-02)
is equal to the speed agree detection level (L04-03) plus or minus the speed agree detection
width (L04-04).
• U01-02 = (L04-03 ± L04-04)
Frequency Detect
When enabled, the Control Method in A01-02 is temporarily overridden to V/f. All other functions for
the new control method are not restricted. Certain programming may need to be done to clear up
any OPE conditions that may occur as a result of the change in control method during this mode. It is
up to the user to determine if a special function may cause an unsafe condition during testing. Since
this feature will be used mainly for No-Load Brake type hoists, many of the inherent safety checks
will become disabled. It may be desirable to disable functions such as Ultra-Lift, but desirable to
leave Limit Switch functions enabled. The user will need to determine what functions are being used.
If unsure, it is best to ensure that the function is disabled (either by programming or MFDI in OFF
state) before running the drive/motor in this mode.
Monitor Selection
The top level in the operation mode allows the viewing of four monitor variables. They are Fref, Fout,
Iout, and User-Selected monitor. This user-selected monitor can be selected from the following
table. See the Monitor Parameters table on page 5-131 for available monitors by control method.
The digital operator has parameter COPY capabilities via built-in non-volatile memory. The digital
operator can READ all of the parameters in the Drive and store them for later, and then WRITE back
to the Drive or into a Drive with the same product code and software number. In order to read the
parameter values and store them into the digital operator, select O04-02 = 1 (Enabled). If you
attempt to READ the data, which overwrites any previously stored data, without first setting
O04-02 = “1: Enabled,” you will get the following error:
RDER
READ DATA ERROR
After setting O04-02 = 1 (Enabled), it is possible to store parameter values in the digital operator by
setting O04-01 = 1 (INV OP READ). A successful READ of the parameter values will display:
END
READ COMPLETE
COPY
OP INV COPYING
END
COPY COMPLETE
An error may occur while writing the parameter values to the Drive. If an error is displayed, press any
key to cancel the error display and return to parameter O04-01. Error displays and their meanings
are covered in Chapter 6: Troubleshooting of Copy Function Related Faults.
It is possible to compare the parameter values stored in the digital operator with the parameter
values currently in the Drive by using the VERIFY function. This VERIFY function should not be
confused with the “-VERIFY-” that is displayed on the digital operator when viewing the “Modified
Constants” menu. To VERIFY the parameter values in the Drive as compared with those stored in
the digital operator, set O04-01 = 3 (OP INV VERIFY). During the comparing of the parameter
values into the drive the digital operator will display:
VRFY
DATA VERIFYING
END
VERIFY COMPLETE
VYE
VERIFY ERROR
The digital operator will not display which parameters did not match, only that the verification found
discrepancies in some parameter values.
NOTE: In order to properly use the COPY or VERIFY functions, the following Drive information
must be identical between the Drive that the parameters were read from and the Drive that
the parameters are written to:
U01-44 ASR Out w/o Filter Output monitor from Speed Control loop (Primary Delay filter %
input value). 100% is displayed at motor rated secondary
current.
U01-50 Hook Height Percentage of Hook height is displayed. This will display 0% %
until the system is homed.
U01-51 Motor Revolution Number of revolutions after Home with respect to Home. Revs
Troubleshooting
This page intentionally left blank.
Alarm
Fault
Code Fault/Alarm Description Corrective Action
AS1 (flashing) Anti-Shock Indicator. When the
Anti-Shock function is triggered, this
1. No action is required. X
Anti-Shock alarm will be displayed on the keypad
for the duration of time set via C07-
22.
BB (flashing) External Base Block Indicator. The 1. Check constants H01-01 through
flashing base block signal is the H01-08 for proper programming.
X
Base Block result of a multi-function input in the
terminal strip. The base block 2. Check terminal status (U01-10).
indicates that the drive’s IGBTs have
been disabled. The motor will begin
coasting when the base block input is
received. If a RUN command is still
present when the BB signal is
removed, the output voltage will be
restored to the previous operating
level and operation will continue at
the previously commanded
frequency.
BE0 (flashing) Brake answer back signal is lost 1. Check brake answer back circuit. X
during run. While running, the multi-
X
Brake Ans Lost function input brake answer back 2. Check terminal status. (U01-10)
(H01-0x = 58) is lost.
BE0-2 Brake 2 answer back signal is lost 1. Check brake answer back circuit. X
during run. Brake Answer-Back 2
X
Brake2Ans Lost closes during operation. 2. Check terminal status. (U01-10)
BE3 Brake Release Fault. The BE3 fault 1. Please reference encoder related
indicates that the drive has released faults on page 6-16.
X
Brake Release NG the brake and commanded the drive
to run, but it has not detected the
expected encoder feedback. A BE3
fault will occur if the pulses received
during the BE3 detection time (C08-
06) are less than the expected
number of pulses (C08-07).
Cant Run User is trying to give a run command 1. Turn on Drive Enable Multi-
while a FWD or REV is present at Function Input.
X
Drive Not Ready Power Up.
2. Check H01-01 to H01-08
programming.
3. Change B03-10 to allow run at
power up.
Can’t SW Can’t Switch - Motor Running. The 1. Allow the motor to come to a stop
user is trying to enable or disable the before enabling or disabling the
X
Motor Running Digital Changeover MFDI (H01-XX = Digital Changeover MFDI.
1D), while the motor is still running.
Memobus Com Err alarm defined by H05-04. 2. Check H05-01 through H05-05
for proper programming.
CPF07 Terminal Board Connection Error. 1. Turn off the power and reconnect
the terminal board.
X
There is a fault connection between
CPF08 the terminal board and the control 1. If the problem continues, replace
board. the control board or the entire
drive. Contact Magnetek for
instructions on replacing the
control board.
board and the drive. The hardware is board and the drive.
damaged.
2. If the problem continues, replace
the control board or the entire
drive. Contact Magnetek for
instructions on replacing the
control board.
CPF24 Drive Unit Signal Fault. The drive 1. If the problem continues, replace
capacity cannot be detected correctly the control board or the entire
X
EF1 External fault occurs on Terminal S1. 1. Check constant H01-01 for
proper programming.
X X
External Alarm or fault defined by the External
Fault 1 Fault Selection table (table 5-80 on 2. Check the conditions for input
page 5-96). terminal S1.
EF2 External fault occurs on Terminal S2. 1. Check constant H01-02 for
proper programming.
X X
External Alarm or fault defined by the External
Fault 2 Fault Selection table (table 5-80 on 2. Check the conditions for input
page 5-96). terminal S2.
EF3 External fault occurs on Terminal S3. 1. Check constant H01-03 for
proper programming.
X X
External Alarm or fault defined by the External
Fault 3 Fault Selection table (table 5-80 on 2. Check the condition of the input
page 5-96). terminal S3.
EF5 External fault occurs on Terminal S5. 1. Check constant H01-05 for
proper programming.
X X
External Alarm or fault defined by the External
Fault 5 Fault Selection table (table 5-80 on 2. Check the condition of the input
page 5-96). terminal S5.
EF6 External fault occurs on Terminal S6. 1. Check constant H01-06 for
proper programming.
X X
External Alarm or fault defined by the External
Fault 6 Fault Selection table (table 5-80 on 2. Check the condition of the input
page 5-96). terminal S6.
EF7 External fault occurs on Terminal S7. 1. Check constant H01-07 for
proper programming.
X X
External Alarm or fault defined by the External
Fault 7 Fault Selection table (table 5-80 on 2. Check the condition of the input
page 5-96). terminal S7.
EF8 External fault occurs on Terminal S8. 1. Check constant H01-08 for
proper programming.
X X
External Alarm or fault defined by the External
Fault 8 Fault Selection table (table 5-80 on 2. Check the condition of the input
page 5-96). terminal S8.
GF During operation, the inverter sums 1. Disconnect motor from drive and
the currents of all three motor check it for shorts using a
X
HBB or External Base Block Indicator. The 1. Check signal status at the input
flashing Hardware Base Block signal terminals H1 and H2.
X
KLX Klixon Circuit Alarm. Input by MFDI 1. Check Motor for Overtemp.
H01-0x = 56 or 57.
X
LF2 Output Current Imbalance. One or 1. Check for faulty wiring or poor/
more of the phases in the output loose connections on the output
X
Output Current current are lost. side of the drive.
Imbalance
2. Correct the wiring.
3. Measure the line-to-line
resistance for each motor phase.
Ensure all values match.
4. Replace the motor.
LL1 (flashing)
Lower Limit 1—SLOW DOWN
Indicator. Lower Limit 1—SLOW
1. May not require corrective action. X
Lower Limit 1 Err DOWN is input (switch status is 2. Check the Limit Switches
changed). position.
3. Check the Limit Switches
condition.
Oper Disconnect running, and the run command was 2. Verify O02-06 setting.
initiated via the keypad RUN key.
SC Short Circuit Fault. The inverter has 1. Disconnect the motor from the
detected an output short circuit inverter.
X
Short Circuit condition.
2. Check for a short circuit in the
motor or wiring using a megger.
TST END Exceeded the 10 minute time limit. 1. Ensure the test mode MFDI is
OFF.
X
Exit Test Mode
2. Reset the fault (Fault Reset
MFDI, Keypad, or cycle power)
3. Ensure that test mode is not used
for normal operation.
Upper Limit 1 Err DOWN switch status is changed. 2. Check the limit switches location.
3. Check the limit switches
condition.
UL2 Upper Limit 2—STOP Indicator. 1. May not require corrective action. X
Upper Limit 2 Err Upper Limit 2—STOP switch status 2. Check the limit switches location.
is changed.
3. Check the limit switches
condition.
UV4 Gate Drive Board Undervoltage. 1. Cycle power to the drive and see
if the fault reoccurs.
X X
GC Undervolt Voltage drop in the gate drive board
circuit. 2. If the problem continues, replace
Exclusive to 4810 and 41090 models. either the gate drive board or the
entire drive. For instructions on
replacing the gate drive board,
contact Magnetek or a Magnetek
representative.
OPE01 kVA Setting Error. Inverter kVA setting 1. Check O02-04 constant for proper
range is incorrect. kVA.
kVA Selection
OPE03 Multi-Function Input Setting Error. 1. Check the settings for H01-01 to H01-
10, verify that the same input is not
Terminal Set values other than “F” are
duplicated. used twice.
OPE16 Weight Measurement. Full load torque 1. Satisfy condition C10-09 > C10-10.
is less than no load torque.
Weight Measure
OPE24 Slack Cable. Incorrect setup. 1. Satisfy condition C11-04 < C11-06
and
Slack Cable C11-05 < C11-07.
Definition
A speed deviation fault means that the drive output is not able to follow the commanded speed
reference. This is possible if there is not enough torque available to follow the internal speed
reference. Therefore, speed deviations will typically occur when the drive is at its programmed
torque limit. In addition, if the drive receives erratic, or missing, encoder pulses, speed deviations are
also possible. If the initial drive tuning and start-up of the system was successfully completed and
the crane has been in operation without any faults, then the occurrence of this fault most likely
indicates that something mechanical with the system has changed or drive parameters were
changed (i.e., failed encoder, load snag, crane overload, change in acceleration or deceleration
times, etc.).
Corrective Action
1. Do NOT continue to operate the hoist.
NOTE: Continued attempts to operate the hoist with speed deviation faults occurring can
result in loss of control of the load under certain circumstances.
2. As a precaution the load float time, parameter C08-10 should be set to zero until the source of
the speed deviation fault has been determined and corrected.
3. Verify if the load has snagged or if there is a load on the hook that exceeds capacity.
4. Check the alignment of the encoder pulse wheel with the sensor head, or the encoder shaft
coupling (depending on the type of encoder used). If the pulse wheel is misaligned or the shaft
coupling is loose the drive will get erratic pulse signals or no signals at all causing a speed
deviation fault or PGO (Pulse Generator Open) fault. Repairs to the encoder wheel or shaft
coupling should be made immediately before again attempting to operate the hoist.
5. If the encoder appears to have no mechanical problems, the encoder cable should be checked
for damage and replaced if a problem is found.
5.1 Each of the encoder wires should be checked for continuity.
5.2 The wires should be checked for shorts between any two wires.
5.3 The wires should be checked for shorts to the shield or ground.
5.4 Visually inspect the cable for damage that may be causing intermittent problems.
6. If the encoder feedback system checks out mechanically and electrically, then the last physical
check to make is for something in the mechanical system that might be resisting normal
operation. One example may be the brake is not opening fully and is causing enough drag to
prevent the system from operating at commanded speed.
Definition
The pulse generator signal missing fault indicates that the drive has detected a problem with
encoder feedback. This fault will typically occur if the drive doesn’t receive any encoder feedback
pulses while it is commanded to run or encoder wiring has a discontinuity.
NOTE: The “X” in PGO-X-S and PGO-X-H depicts either a “1” if the PG-X3 is seated in connector
CN5-C, or a “2” if the PG-X3 is seated in connector CN5-B.
Corrective Action
1. Do NOT continue to operate the hoist in the event of a PGO-X-H fault or repeated PGO-X-S
faults.
NOTE: Continued attempts to operate the hoist with PGO faults occurring can result in loss of
control of the load under certain circumstances.
2. As a precaution, the load float time, parameter C08-10, should be set to zero until the source of
the PGO Fault has been determined and corrected. Disable PGO hardware detection with
F01-06 or F01-08.
3. Check the alignment of the encoder pulse wheel with the sensor head, the encoder shaft
coupling (depending on the type of encoder used), or check for a failed encoder sensor head. If
one of these conditions exists the drive will get erratic pulse signals or no signal at all causing a
speed deviation fault or PGO fault. Repairs to the encoder wheel or shaft coupling should be
made immediately before attempting to operate the hoist again.
4. If the encoder appears to have no mechanical problems, the encoder cable should be checked
for damage and replaced if a problem is found.
4.1 Each of the encoder wires should be check for continuity.
4.2 The wires should be checked for shorts between any two wires.
4.3 The wires should be checked for shorts to the shield or ground.
4.4 Visually inspect the cable for damage that may be causing intermittent problems.
5. If the encoder feedback system checks out, then check for physical obstruction to motor rotation
such as brake failing to open.
Definition
The BE1 fault indicates that the drive has released the brake, but has not started to accelerate the
motor when it detects more than the expected encoder feedback. A BE1 fault will occur if the pulses
received during the BE1 detection time (C08-04) are greater than the expected number of pulses
(C08-05). This is typically caused by the drive/motor having insufficient torque to suspend the load.
Correction Action
1. Check the encoder cable for damage and proper grounding. Replace it if a problem is found.
1.1 Each of the encoder signals should be checked for excessive noise.
1.2 The shielded encoder cable should be properly grounded.
1.3 Visually inspect the cable for damage that may be causing intermittent problems.
2. Check the alignment of the encoder pulse wheel with the sensor head, or the encoder shaft
coupling (Depending on the type of encoder used). If the pulse wheel is misaligned or the shaft
coupling is loose the drive may get erratic pulse signals possibly causing a BE1 fault. Repairs to
the encoder wheel or shaft coupling should be made immediately before again attempting to
operate the hoist.
3. If none of the above steps has identified a valid problem(s), only then should the BE1 detection
parameters be adjusted.
NOTE: It is desirable to have as fast a fault reaction time as possible without causing
nuisance trips.
4. Increase C08-05 to no more than 800 pulses.
Definition
The BE2 fault indicates that the drive was unable to develop sufficient torque before releasing the
brake. A BE2 fault occurs when the torque (U01-09) is less than the Initial Forward Brake Torque
(C08-16) during the current feedback timer (C08-02) at start. This typically indicates that the brake is
slipping while torque is building up in the motor before releasing the brake.
NOTE: This fault typically indicates a failed brake. Power should NOT be removed while this
alarm is active and the load should be moved to a safe location and lowered before
proceeding with any corrective action.
Corrective Action
1. Check the brake for proper operation and adjustment. If the brake does not set, is improperly
adjusted or is excessively worn, it may not be able to hold the load. This will allow the encoder
pulses received while torque is building up in the motor.
2. Check the encoder cable for damage and proper grounding. Replace it if a problem is found.
2.1 Each of the encoder signals should be checked for excessive noise.
2.2 The shielded encoder cable should be properly grounded.
2.3 Visually inspect the cable for damage that may be causing intermittent problems.
3. Check the alignment of the encoder pulse wheel with the sensor head, or the encoder shaft
Definition
The BE3 fault indicates that the drive has released the brake and commanded the drive to run, but
has not detected the expected encoder feedback. A BE3 fault will occur if the pulses received during
the BE3 detection time (C08-06) are less than the expected number of pulses (C08-07).
NOTE: Depending on the condition of the crane and control system, the load may drift during the
BE3 detection time until the brake is again set. If giving a run command, the BE3 fault
should be detected before a PGO fault would be detected.
Corrective Action
1. Check the brake for proper operation. If the brake does not open the drive will not see the proper
number of encoder pulses returned and will post this fault.
2. Check the alignment of the encoder pulse wheel with the sensor head, or the encoder shaft
coupling (depending on the type of encoder used). If the pulse wheel is misaligned or the shaft
coupling is loose the drive will get erratic pulse signals or no signals at all possibly causing a
BE3 fault. Repairs to the encoder wheel or shaft coupling should be made immediately before
again attempting to operate the hoist.
3. If the encoder appears to have no mechanical problems, the encoder cable should be checked
for damage and replaced if a problem is found.
3.1 Each of the encoder wires should be checked for continuity.
3.2 The wires should be checked for shorts between any two wires.
3.3 The wires should be checked for shorts to the shield or ground.
3.4 Visually inspect the cable for damage that may be causing intermittent problems.
4. If none of the above steps has identified a valid problem(s), only then should the BE3 detection
parameters be adjusted.
NOTE: It is desirable to have as fast a fault reaction time as possible without causing
nuisance trips.
5. Ensure that C08-04 is equal to the brake’s mechanical delay time.
6. Increase the value of C08-06 to no more than 1 second.
7. Decrease the value of C08-07 to no less than 10 pulses.
Definition
The BE6 alarm indicates that the drive has commanded the brake to set but it has detected more
encoder pulse feedback than expected. A BE6 alarm will occur if the number of pulses received
during the BE6 detection time (C08-12) is greater than the expected number of pulses (C08-13). The
drive will initiate Load Float for the duration of the BE6 alarm.
NOTE: This fault typically indicates a failed brake. Power should NOT be removed while this
alarm is active and the load should be moved to a safe location and lowered before
proceeding with any corrective action.
NOTE: The BE6-Brake Proving Alarm is re-verified during every brake set, including brake sets
that occur after the BE6 alarm is posted. The BE6 alarm will turn off if a successful
brake check occurs after an initial BE6 alarm condition is posted based on the
setting of C08-19.
Corrective Action
1. Check the brake for proper operation and adjustment. If the brake does not set, is improperly
adjusted or is excessively worn, it may not be able to hold the load. This will allow the encoder
pulses received during the detection time to exceed the set point.
2. Check the encoder cable for damage and proper grounding. Replace it if a problem is found.
2.1 Each of the encoder signals should be checked for excessive noise.
2.2 The shielded encoder cable should be properly grounded.
2.3 Visually inspect the cable for damage that may be causing intermittent problems.
3. Check the alignment of the encoder pulse wheel with the sensor head, or the encoder shaft
coupling (Depending on the type of encoder used). If the pulse wheel is misaligned or the shaft
coupling is loose the drive may get erratic pulse signals possibly causing a BE6 alarm. Repairs
to the encoder wheel or shaft coupling should be made immediately before again attempting to
operate the hoist.
4. If none of the above steps has identified a valid problem(s), only then should the BE6 detection
parameters be adjusted.
NOTE: It is desirable to have as fast a fault reaction time as possible without causing
nuisance trips.
5. Ensure that C08-11 is equal to the brake’s mechanical delay time.
6. Increase the value of C08-13.
Definition
The BE8 alarm indicates that the drive has detected that the brake slipping after the brake is set. A
BE8 alarm will occur if the drive detects that the load is moving greater than the brake Slip Detection
Speed (C08-23) when the brake is set. When this occurs, the drive will go into load float while the
brake is set.
NOTE: This alarm typically indicates a failed brake. Power should NOT be removed while this
alarm is active and the load should be moved to a safe location and lowered before
proceeding with any corrective action.
Definition
An over current fault is caused if the output current exceeds 200% of the inverter rated output
current. This fault can be caused by short circuits in the wiring or in the motor, and it can also be
caused by parameters that are not adjusted properly. One other cause of this fault could be erratic or
no encoder feedback. In the last instance, the drive is trying to command the motor to hold a
position, but due to the encoder problem, is unable to find the correct position. This would cause the
drive to increase current output to the motor in an attempt to correct the position until an over current
fault occurs.
Corrective Action
1. Check the motor wiring and the motor itself for a short between phases.
2. Check the alignment of the encoder pulse wheel with the sensor head, or the encoder shaft
coupling (depending on the type of encoder used). If the pulse wheel is misaligned or the shaft
coupling is loose the drive will get erratic pulse signals or no signals at all possibly causing an
OC fault. Repairs to the encoder wheel or shaft coupling should be made immediately before
again attempting to operate the hoist.
3. If the encoder appears to have no mechanical problems, the encoder cable should be checked
for damage and replaced if a problem is found.
3.1 Each of the encoder wires should be check for continuity.
3.2 The wires should be checked for shorts between any two wires.
3.3 The shield should be check for proper grounding.
3.4 The wires should be checked for shorts to the shield or ground.
3.5 Visually inspect the cable for damage that may be causing intermittent problems.
4. If none of the above steps has identified a valid problem(s), check if any of the torque limit
parameters (C07-01 to C07-04) have been changed. If these parameters have been changed to
allow a higher torque value, it could cause overcurrent trips.
NOTE: Changing these parameters could also induce speed deviation or overload faults. Only a
trained technician should modify these parameters. It is desirable to have as fast a fault
reaction time as possible without causing nuisance trips.
CPEr Control Method Mismatch. Control method • Verify the control method for the parameters
of the parameters to be loaded onto the drive to be loaded onto the drive and the control
and the control method set to the drive do not method on the drive to which those
match. parameters will be written.
• Set the same control method using
parameter A01-02 and retry.
CSEr Copy Unit Error. Hardware fault. Replace the operator or the USB Copy Unit.
ndAT Model, Voltage Class, Capacity Mismatch. • Make sure model numbers and
• The drive from which the parameters were specifications are the same for both drives.
copied and the drive to which the • Make sure all connections are correct, and
parameters will be written have different copy the parameter settings onto the USB
electrical specifications, capacities, are set Copy Unit or the operator.
to different control methods, or are different
models.
• The device being used to write the
parameters is blank and does not have any
parameters saved on it.
WA R N I N G
Do NOT touch any circuit components while AC main power is on or immediately after the
main AC power is disconnected from the unit. You must wait until the red “CHARGE” lamp is
extinguished. It may take as long as 10 minutes for the charge on the main DC bus capacitors
to drop to a safe level. Failure to adhere to this warning could result in serious injury.
WA R N I N G
Do NOT touch any circuit components while AC main power is on or immediately after the
main AC power is disconnected from the unit. You must wait until the red “CHARGE” lamp is
extinguished. It may take as long as 10 minutes for the charge on the main DC bus capacitors
to drop to a safe level. Failure to adhere to this warning could result in serious injury.
NOTE: When handling boards always use electrostatic discharge protection. Keep the boards in
the ESD bag as long as you can. Do not lay the board on any surfaces without ESD
protection. When handling, always hold the board from the edges and do not touch the
components. Installation should be performed only by qualified personnel who are familiar
with this type of equipment and the hazards involved.